Combined midsole/insole

ABSTRACT

Described herein are devices and techniques for solving the problems, such as high costs and intensive labor, associated with individual cutting and lamination of each component of a multilayered article of manufacture, particularly a footwear article. The combined midsole/insole described herein is cut from a layered composition having a Strobel (or insole board) layer, a cushioning layer, and a textile layer. The Strobel layer, the cushioning layer, and the textile layer are needle-punched or laminated together to form the layered composition. The layered composition may be produced as a sheet of material or be produced as a roll of material without delamination or separation of the layers.

BACKGROUND

1. Field of the Invention

The present invention relates generally to layered compositions and more particularly to a layered composition comprising three or more layers suitable for combined midsole/insole production.

2. Discussion of Background Information

Shoes are typically made from a combination of materials. As shown in FIG. 1A, the structure of a shoe 100 typically includes an upper 101 and a sole 103. The sole 103 is comprised of layers commonly referred to as an outsole 105, midsole 107, and insole 109. The outsole 105 is typically constructed from a rubber and has an exterior surface that contacts the ground. The components of the midsole 107 will vary according to manufacturer, but typically provide most of the cushioning. The midsole 107 may comprise foam (e.g., ethylene vinyl acetate) or polyurethane surrounding another cushioning such as gel or liquid silicone. The insole 109 is typically constructed from a thin layer of foam (e.g., EVA). The sole 103 also typically includes a textile material layer known as the footbed (or sock liner) 111 disposed over the insole and in contact with the foot or sock inside the shoe 100. The materials used in making the midsole 107, insole 109, and footbed 111 layers described above are die-cut individually and then, one at a time, laminated together and to the outsole 105 as shown in FIG. 1B. The upper 101 is attached or “lasted” to one or more of the midsole 107, insole 109, and footbed 111 during the lamination. This is a labor-intensive process that adds substantially to the cost of production.

SUMMARY OF THE INVENTION

It would be desirable in shoe production applications to produce a combined midsole/insole which provides cushioning and support for a shoe and may be cut from a layered composition and assembled into a shoe as one piece.

Described herein are devices and techniques for solving the problems, such as high costs and intensive labor, associated with individual cutting and lamination of each component of a multilayered article of manufacture, particularly a footwear article. The combined midsole/insole described herein is cut from a layered composition having a Strobel (or insole board) layer, a cushioning layer, and a textile layer. The Strobel layer, the cushioning layer, and the textile layer are needle-punched or laminated together to form the layered composition. The layered composition may, for example, be produced as a sheet of material or be produced as a roll of material.

In one aspect, at least one embodiment described herein provides a layered composition. The layered composition includes three or more layers suitable for combined midsole/insole production. The three or more layers include a first layer. The first layer includes a Strobel or insole board. The three or more layers also include a second layer. The second layer includes a cushioning material. The three or more layers also include a third layer. The third layer includes a textile material, wherein the first layer, second layer, and third layer are needle-punched or laminated together so as to form a layered composition, the layered composition being cuttable to produce at least one combined midsole/insole.

Any of the embodiments described herein can include one or more of the following embodiments. In some embodiments the cushioning material includes at least one of polyester needle-punch, recycled fiber, viscose fibers, ethylene vinyl acetate (EVA), rubber, neoprene, or polyurethane. In some embodiments the Strobel or insole board includes at least one of a non-woven, stitch-bounded, fibrous material, polyester, polypropylene, cotton, nylon, wool, or viscose fibers. In some embodiments the textile material includes at least one of a woven textile, a non-woven textile, a knit textile, polyester, nylon, cotton, or wool.

In some embodiments the second layer is positioned between the first layer and the third layer. In some embodiments the first layer is positioned between the second layer and the third layer. In some embodiments a minimum diameter of a cylinder around which the layered composition is rollable without delamination or separation is less than 40 millimeters. In some embodiments the at least one combined midsole/insole is configured for assembly with at least one of an outsole and an upper to produce a shoe.\

In one aspect, at least one embodiment described herein provides a method for making a combined midsole/insole. The method includes providing a first layer. The first layer includes a Strobel or insole board. The method also includes providing a second layer. The second layer includes a cushioning material. The method also includes providing a third layer. The third layer includes a textile material. The method also includes needle-punching or laminating the first layer, the second layer, and the third layer together to form a layered composition.

Any of the embodiments described herein can include one or more of the following embodiments. In some embodiments the method includes cutting the layered composition to produce at least one combined midsole/insole. In some embodiments cutting includes die-cutting. In some embodiments The method also includes assembling the at least one combined midsole/insole with at least one additional component to produce a shoe. In some embodiments the at least one additional component is at least one of an outsole or an upper. In some embodiments the shoe includes one of the at least one combined midsole/insole, an outsole, and an upper.

In one aspect, at least one embodiment described herein provides a shoe. The shoe includes an outsole. The shoe also includes a combined midsole/insole. The combined midsole/insole includes a first layer. The first layer includes a Strobel or insole board. The combined midsole/insole also includes a second layer. The second layer includes a cushioning material. The combined midsole/insole also includes a third layer. The third layer includes a textile material, wherein the first layer, second layer, and third layer are needle-punched or laminated together so as to form a layered composition, the layered composition being cuttable to a desired shape. The shoe also includes an upper.

Any of the embodiments described herein can include one or more of the following embodiments. In some embodiments the third layer of the combined midsole/insole is a footbed. In some embodiments the outsole and the combined midsole/insole are at least one of needle punched, glued, laminated, or sewn together. In some embodiments the upper and the combined midsole/insole are at least one of needle punched, glued, laminated, or sewn together.

BRIEF DESCRIPTION OF THE DRAWINGS

One will better understand these and other features, aspects, and advantages of the present invention following a review of the description, appended claims, and accompanying drawings:

FIG. 1A is a cross-sectional view of a shoe constructed in accordance with the prior art.

FIG. 1B is an exploded view of each layer of a shoe constructed in accordance with the prior art.

FIGS. 2A-2C are cross-sectional views of various layered compositions in accordance with various embodiments.

FIG. 3A is a diagram of a system for producing a layered composition in accordance with various embodiments.

FIG. 3B is a diagram of a system for producing a combined midsole/insole in accordance with various embodiments.

FIGS. 4A-C are cross-sectional diagrams of various types of shoes constructed with a combined midsole/insole in accordance with various embodiments.

FIG. 5 is a flow chart of a method for making a combined midsole/insole in accordance with various embodiments.

DETAILED DESCRIPTION

The devices and techniques described herein solve the problems associated with standard footwear assembly such as the increased labor and cost of individually cutting and laminating each component of a multilayered article of footwear. The combined midsole/insole described herein is cut from a layered composition having a Strobel (or insole board) layer, a cushioning layer, and a textile layer. The Strobel layer, the cushioning layer, and the textile layer are needle-punched or laminated together to form the layered composition. The layered composition may be produced as a sheet of material or be produced as a roll of material. In embodiments produced as a roll of material the layered composition may be designed to be rolled without delamination or separation of the layers.

As shown in FIGS. 2A-2C, various embodiments of a layered composition 200 for use in the production of a combined midsole/insole of a shoe may include at least a first layer 201, a second layer 203, and a third layer 205. As shown in FIG. 2A, various embodiments may include a bottom layer corresponding to the first layer 201 and an intermediate layer corresponding to the second layer 203. In various other embodiments, illustrated in FIG. 2B, a bottom layer may correspond to the second layer 203 and the intermediate layer may correspond to the first layer 201. It will be apparent in view of this disclosure that any number of additional layers (e.g., 207 as shown in FIG. 2C) may be included in the layered composition 200 and that any arrangement of such layers 201, 203, 205, 207 may be suitable in accordance with various embodiments.

The first layer 201 may be made of any material, such as, for example a Strobel or insole board, suitable for slip lasting, board lasting, Strobel lasting, or any combination thereof. Strobel or insole boards in accordance with various embodiments may be any stiffening material which remains sufficiently flexible for use in a shoe (e.g., a non-woven, stitch-bounded, fibrous material, polyester, polypropylene, cotton, nylon, wool, viscose fibers, leather, combinations thereof, and/or any other suitable material). Thereby, a layered composition 200 in accordance with various embodiments may provide a suitable layer of material for lasting an upper to a combined midsole/insole produced from the layered composition 200.

The second layer 203 may be made of any material suitable for providing cushioning in a shoe. In various embodiments such cushioning material may include, for example, polyester needle-punch, recycled fiber, viscose fibers, ethylene vinyl acetate (EVA), rubber, neoprene, polyurethane, gel, combinations thereof, and/or any other suitable material. Such cushioning may provide suitable impact absorption and/or comfort in shoes having a combined midsole/insole produced from a layered composition 200 in accordance with various embodiments.

The third layer 205 may be made of any material suitable for providing a footbed or sock liner in a shoe. In various embodiments such materials may include any suitable textile material (e.g., any woven textile, any non-woven textile, any knit textile, polyester, nylon, cotton, wool, leather, and/or any other suitable material). Thereby, a layered composition 200 in accordance with various embodiments may provide a suitable layer of material for functioning similarly to a footbed in a combined midsole/insole produced from the layered composition 200.

In further embodiments, such as the embodiment illustrated in FIG. 2C, one or more additional layers 207 may be made of one or more of any of the materials described above with reference to the first layer 201, second layer 203, and third layer 205. Each additional layer 207 may also be made of any other material or substance suitable for a functional and/or aesthetic purpose of that particular additional layer 207. Such additional layers 207 may provide, in various embodiments, additional stiffness, cushioning, warmth, breathability, support, moisture removal, visual appeal, and/or any other added functionality or aesthetic property. Such layers may include foam cushioning, gel cushioning, heel support, arch support, toe reinforcement, heel tips, insulation, decoration, etc.

As shown in FIG. 3A, layers of material (e.g., the first layer 201, second layer 203, and third layer 205) may be needle-punched or laminated together (e.g., by a needle-punching or laminating machine 301) to form a layered composition 200. The layered composition 200 may, in various embodiments, be produced as a roll 303 of layered composition 200 to be cut into one or more combined midsole/insoles 307 as shown in FIG. 3B. In such embodiments it is important, although not absolutely required, that the flexibility of the layered composition 200 and the fixation strength of the lamination and/or needle-punching be sufficient to prevent delamination when the layered composition 200 is rolled. In various embodiments the minimum cylinder diameter about which the layered composition can be rolled without delamination or separation of the layers (e.g., 201, 203, 205) is less than 40 millimeters.

FIG. 3B illustrates that, in various embodiments, a roll 303 of layered composition 200 may be cut (e.g., by die-cutting) using, for example, a cutting machine 305. Cutting the layered composition 200 into a desired shape may, in various embodiments, produce a combined midsole/insole 307 for assembly into a shoe.

FIG. 3A illustrates a system for producing a layered composition and FIG. 3B illustrates a system for producing combined midsole/insoles. Although the particular embodiments illustrated by FIGS. 3A and 3B show rolls 303 of layered composition 200 which are produced and then subsequently cut into a combined midsole/insole 307, it will be apparent in view of this disclosure that the layered composition 200 may be produced in any number of shapes and sizes (e.g., rectangular sheets, octagonal sheets, circular sheets, stacks of sheets, bundles of sheets) and is not limited to being formed into a roll 303. It will be further apparent in view of this disclosure that the needle-punching and/or laminating machine 303 and the cutting machine 305 may be arranged in immediate sequence and/or incorporated into the same machine such that the layered composition 200 is produced as a plurality of combined midsole/insoles 307 and/or any other desired shape.

In some embodiments, a material producer (not shown) may produce rolls 303 (or sheets, etc.) of layered composition 200 which may then be sold to a shoe manufacturer (not shown). The shoe manufacturer may then cut the roll 303 of layered composition 200 to provide a plurality of combined shoe midsole/insoles 307 for assembly into a shoe (e.g., any of 400, 430, and/or 460 as shown in FIGS. 4A-4C).

In other embodiments, the material producer may produce and cut the layered composition 200 to provide a plurality of combined shoe midsole/insoles 307. The combined shoe midsole/insoles 307 may then be sold to a shoe manufacturer for assembly into a shoe (e.g., any of 400, 430, and/or 460 as shown in FIGS. 4A-4C).

A combined midsole/insole 307 in accordance with various embodiments may be used in any type of shoe (e.g., an athletic shoe 400 as shown in FIG. 4A, a boot 430 as shown in FIG. 4B, and a high heeled shoe 460 as shown in FIG. 4C). As shown in FIGS. 4A-4C, such shoes 400, 430, 460 generally include an upper 401 and a sole comprising at least an outsole 405 and a combined midsole/insole 407. In some embodiments additional components may be added to the shoe to provide additional desired features such as, for example, cushioned heel supports 409, steel toe reinforcements 431, arch supports 433, and/or heel tips 461 (also referred to as a “heel caps” or “taps”)

Accordingly, and as further illustrated by comparing the shoes of FIGS. 4A-4C with the prior art illustrated by FIG. 1, a combined midsole/insole 407 produced from a layered composition 200 as described herein substantially reduces the time and labor associated with shoe construction. Such reductions are achieved by reducing the number of cuts made to midsole, insole, and footbed materials and further by reducing the number of pieces that must be assembled and/or laminated during shoe construction.

FIG. 5 illustrates a method 500 for producing a layered composition cuttable to produce a combined midsole/insole in accordance with various embodiments of the present disclosure comprising the steps of providing a first layer comprising a Strobel or insole board 501, providing a second layer comprising a cushioning material 503, providing a third layer comprising a textile material 505, and needle-punching or laminating the first layer, the second layer, and the third layer together to form a layered composition 507.

In various embodiments the steps of providing a first layer comprising a Strobel or insole board 501, providing a second layer comprising a cushioning material 503, and providing a third layer comprising a textile material 505 may include, but are not limited to, providing a first layer 201, a second layer 203, and a third layer 205 as described above with reference to FIGS. 2A-2C.

The step of needle-punching or laminating the first layer, the second layer, and the third layer together to form a layered composition 507 may, in various embodiments include needle-punching and/or laminating each layer together to form a layered composition. In various embodiments, the layered composition may include, but is not limited to, a layered composition 200 as described above with reference to FIGS. 2A-2C. Needle-punching and/or laminating to form a layered composition may be performed by hand or by machine and may, in some example embodiments, be performed using a system for producing a layered composition as described hereinabove with reference to FIGS. 3A and 3B.

In some embodiments, an optional additional step of cutting the layered composition to produce at least one combined midsole/insole 509 is performed. In various embodiments, the combined midsole/insole may include, but is not limited to, a combined midsole/insole 307 as described above with reference to FIG. 3B. For such embodiments the step of cutting may be performed by hand or by machine and may, in some example embodiments, be performed using a system for producing a combined midsole/insole as described hereinabove with reference to FIGS. 3A and 3B. Any method of cutting (e.g., scissors, saw, hot wire, die-cutting) may be used to cut the layered composition and thereby produce the combined midsole/insole(s) in accordance with various embodiments.

Accordingly, a layered composition 200 is provided for producing a combined midsole/insole (e.g., 307), the use of which reduces the time, labor, and cost associated with shoe construction. Although the layered composition 200 is described throughout with reference to application in a footwear product, other applications of the present invention are contemplated, particularly applications requiring multi-layered components having flexibility, supportive stiffness, and cushioning/impact absorption. Such applications may include, for example, construction of various athletic devices, articles of clothing, and/or protective padding.

It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words, which have been used herein, are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. 

What is claimed is:
 1. A layered composition comprising three or more layers suitable for combined midsole/insole production comprising: i) a first layer comprising a Strobel or insole board; ii) a second layer comprising a cushioning material; and iii) a third layer comprising a textile material, wherein the first layer, second layer, and third layer are needle-punched or laminated together so as to form a layered composition, the layered composition being cuttable to produce at least one combined midsole/insole.
 2. The layered composition of claim 1, wherein the cushioning material comprises at least one of polyester needle-punch, recycled fiber, viscose fibers, ethylene vinyl acetate (EVA), rubber, neoprene, or polyurethane.
 3. The layered composition of claim 1, wherein the Strobel or insole board comprises at least one of a non-woven, stitch-bounded, fibrous material, polyester, polypropylene, cotton, nylon, wool, or viscose fibers.
 4. The layered composition of claim 1, wherein the textile material comprises at least one of a woven textile, a non-woven textile, a knit textile, polyester, nylon, cotton, or wool.
 5. The layered composition of claim 1, wherein the second layer is positioned between the first layer and the third layer.
 6. The layered composition of claim 1, wherein the first layer is positioned between the second layer and the third layer.
 7. The layered composition of claim 1, wherein a minimum diameter of a cylinder around which the layered composition is rollable without delamination or separation is less than 40 millimeters.
 8. The layered composition of claim 1, wherein the at least one combined midsole/insole is configured for assembly with at least one of an outsole and an upper to produce a shoe.
 9. A method for making a combined midsole/insole comprising: i) providing a first layer comprising a Strobel or insole board; ii) providing a second layer comprising a cushioning material; iii) providing a third layer comprising a textile material; and iv) needle-punching or laminating the first layer, the second layer, and the third layer together to form a layered composition.
 10. The method of claim 9, further comprising cutting the layered composition to produce at least one combined midsole/insole.
 11. The method of claim 10, wherein the step of cutting further comprises die-cutting.
 12. The method of claim 10, further comprising assembling the at least one combined midsole/insole with at least one additional component to produce a shoe.
 13. The method of claim 12, wherein the at least one additional component is at least one of an outsole or an upper.
 14. The method of claim 12, wherein the shoe comprises one of the at least one combined midsole/insole, an outsole, and an upper.
 15. A shoe comprising: i) an outsole; ii) a combined midsole/insole comprising: i. a first layer comprising a Strobel or insole board; ii. a second layer comprising a cushioning material; and iii. a third layer comprising a textile material, wherein the first layer, second layer, and third layer are needle-punched or laminated together so as to form a layered composition, the layered composition being cuttable to a desired shape; and iii) an upper.
 16. The shoe of claim 15, wherein the third layer of the combined midsole/insole is a footbed.
 17. The shoe of claim 15, wherein the outsole and the combined midsole/insole are at least one of needle punched, glued, laminated, or sewn together.
 18. The shoe of claim 15, wherein the upper and the combined midsole/insole are at least one of needle punched, glued, laminated, or sewn together. 